Soap composition

ABSTRACT

SOAP COMPOSITION AS AN IMPREGNANT FOR SCOURING PADS AND THE LIKE COMPRISES SODIUM NITRITE, POTASSIUM CARBONATE, POLYGLYCOL, SODIUM HIGH LAURIC ACID OIL SOAP, SODIUM TALLOW SOAP AND A FOAM BUILDER.

United States Patent ABSTRACT OF THE DISCLOSURE Soap composition as animpregnant for scouring pads and the like comprises sodium nitrite,potassium carbonate, polyglycol, sodium high lauric acid oil soap,sodium tallow soap and a foam builder.

This invention relates to a soap composition for scouring pads and thelike and methods for making same. In prior art compositions of suchformulations considerable quantities of potassium soap have beennecessary as an important constituent of the detergent composition. Itwill be appreciated that potassium soaps are much more expensive thanthe corresponding sodium soaps. The pres ent invention is predicated onthe utilization of a potassium component other than soap, while all ofthe soap added to the composition is a sodium soap. The inclusion of apotassium component has been found to be efficacious to control fluiditywhen the soap is in a molten condition and is sprayed onto the fibers ofscouring pads and the like.

The soap composition for scouring pads within the purview of the presentinvention may be composed of the following ingredients within thefollowing ranges:

More preferably the above ingredients are employed in the followingranges:

Percent by weight Water 30-45 Sodium nitrite 1. 5-2. 5 Potassiumcarbonate. 5-8 Sodium carbonate 0-5 Sodium high lauric acid soap 5-3030%,] Sodium tallow soap 15-40 Foam builder 2-4 Color and perfume 0-1 Incarrying out the present invention, it is important that the componentsof the soap composition be employed at the amounts set forth herein inorder to obtain the desired results.

It has been found in the course of certain tests to determine theeffectiveness of detergent and soap impregnating compounds in connectionwith steel wool pads for use in cleansing purposes, that a soap made inaccordance with the above formulation may advantageously be used toreplace the soap compositions presently employed in commercial steelwool pads and to fulfill the needs and requirements of the practice.While reference hereinafter is primarily made to steel wool pads, it isto be understood that any other metal or plastic fiber may besubstituted therefor.

In the novel impregnating agent, water is employed at 3,725,288 PatentedApr. 3, 1973 25-50% by Weight of the soap composition to provide a soapwhich may be applied to the scouring pad ribbon by any conventionalmeans, e.g., dipping, spraying, etc. and which sets upon cooling.

Sodium nitrite when employed up to 5% by weight of the soap compositionacts in combination with the other components to provide improved rustresistant properties in steel wool scouring pads. While sodium nitritehas been used in the past for such purposes, the soap composition of thepresent invention provides significantly superior rust inhibitingproperties.

The potassium carbonate employed in the present invention at 25-10% byweight of the soap composition is selected for the source of thepotassium element as opposed to prior art practices where potassium soapmay be the source. It creates a more desirable fluidity in the soapcomposition, as opposed to sodium carbonate, to provide improvedhandling e.g. in spraying and dipping and better distribution of soapthroughout the entire cross section of the scouring pad.

The sodium carbonate which is an optional ingredient, may beparticularly desirable to control the viscosity of the composition, animportant factor in obtaining proper impregnation of the wool pad, aswell as reduce tackiness if and where it is a problem. As indicatedabove, up to 10% and preferably, up to 5% thereof may be employed.

One may, if desired, employ as a further adjuvant in the soapcompositions in this invention polyglycols for reducing dust andpossibly drying out during storage. Typical of the polyglycols which onemay use are polyethylene glycol, sorbitol, maunitol, glycerine and thelike in amounts from O to 6% The sodium high lauric acid soap employedin the present invention at 5-55 by weight of the soap composition maybe made from a high lauric acid oil such as commercial coconut oil, palmkernel and babassu nut oil which has been saponified to provide thepotassium soap. It is preferred to employ coconut oil soaps having lowermoisture contents. Where commercially available sodium coconut oil soapsare employed, it may be necessary to reduce the moisture level of thesoap composition after preparation in order to provide a water contentof 25- 50% by weight.

The sodium tallow soap of the present invention is employed at 5-55 byweight of the soap composition. It is prepared by saponification ofcommercially available tallow or neutralization of fatty acids derivedfrom tallow or other sources that give predominantly palmitic, stearicand oleic acids. It is essential that unsaturated oleic acid which is anormal component of many sodium tallow soaps be at a level of less thanl8% by weight of the total soap composition. It has been found thatlevels of oleic acid in excess of 18% of the total soap compositioncause noticeable foam deterioration.

In preparing the sodium salts of the high lauric acid source and thetallow or equivalent fatty acids, it has been found desirable to preparethe two soaps simultaneously in accordance with common soap makingtechniques employing the conventional kettle boiling process.

The foam builder employed in the present invention at less than 6% byweight of the soap composition may be a saturated fatty alcohol having achain length of C to C In amounts greater than 6% by weight, it has beenfound that the foam builders frequently create handling problems andprovide the soap composition with an undesirable physical appearance.While the lower chain length, e.g., C to C fatty alcohols provideacceptable results from the standpoint of foam characteristics, they maybe less desirable for some uses due to their odor which may beobjectionable. Where the higher chain length, e.g., C to C fattyalcohols are employed, it has been found preferable to use such fattyalcohols in combination to obtain optimum foaming effect. Typical of thefatty alcohols that may be employed in the present invention areoctanol, decanol, tetradecanol, hexadecanol, octadecanol, dodecanolalcohols and the like. Of these fatty alcohols, the dodecanol ispreferred in carrying out the present invention. Where the C to Csaturated fatty alcohols have been employed, particularly satisfactoryresults have been obtained with mixtures of C C and C alcohols. It hasalso been found that the foam builders unexpectedly extend the use lifeof the scouring pads as compared to equivalent pads wherein no foambuilder is added to the soa I t also was found in carrying out thepresent invention that in order to further reduce the rusting wheresteel wool is used in the scouring pad, that the chloride and sulfateion concentration in the soap composition of the present invention mustbe less than 1% by weight of the total composition and preferably lessthan 0.2% by weight. Such ions are commonly a carry-over in salts formedin conventional soap making processes and exist in many commercial soapsources.

While, as hereinbefore stated, the soap compositions of the presentinvention may be applied to scouring pads by any common applicationmeans, it has been found that the soap composition is particularlysuitable for use in a process utilizing a spray application. Heretofore,soap compositions of the prior art, due to their physicalcharacteristics have been unsuitable for spray application on scouringpads. Such soaps, when spray application was attempted, generallyprovided pads having extremely poor appearance, uneven soap distributionand in addition thereto, the spraying resulted in high soap losses inthe manufacturing operations.

A particularly satisfactory product may be prepared with the presentsoap composition or other suitable sprayable detergent which may be soapor synthetic detergent using a method wherein a fiat ribbon of suitablescouring pad wool or fibers having a thickness and width sufiicient toprovide finished scouring pads of desired shape is sprayed with adetergent composition on at least one side. The detergent is suppliedthrough a spray nozzle and pump connected to a suitable source ofsupply. The ribbon then has placed upon it, at spaced intervals, meteredquantities of a detergent core in a semi-solid, plastic, paste-like formwhich is capable of maintaining its position and shape as a discretebody. The detergent may be the same detergent used in spraying or anyother compatible detergent. The frequency of this charge of thesemi-solid core composition and the linear speed of the ribbon are socorrelated as to provide discrete bodies of the core composition on theribbon. The ribbon may then be cut by cutting means at equally spacedintervals to provide each cut strip of ribbon with a unitary, discretebody of soap. In the alternative, if desired, the ribbon may be dividedinto desired lengths by tearing or cutting before applying the core. Thecut ribbon is rolled into a cylinder with the discrete body of detergentin the center and compressed to form a finished scouring pad. As usedherein the term cut refers to the cutting or tearing of steel wool orother ribbons to divide the ribbon into proper length.

In carrying out a preferred embodiment of the present invention, steelwool is the scouring pad fiber employed. It has been found that the typesteel Wool employed may be varied considerably depending upon theabrasiveness and texture desired in the finished scouring pad.Preferably, commercial steel wools having the grades in the order ofabout 1 to are employed. It is preferred to employ long fibered steelwool capable of giving the finished pads desired elasticity and springWhile at the same time reducing the number of short ends which canabrade the users hands.

In carrying out the spraying step in the method of the presentinvention, any spray system capable of handling soap may be employed.

When steel wool ribbon is employed, it is preferred to use a soapcomposition as the detergent to be applied. Typically, spray nozzleshaving orifice diameters of 0.005- 0.025 inch will provide satisfactoryresults with most soap compositions. The soap composition to be sprayedis maintained at a temperature above which the soap is fluid and may beatomized and below which the atomized soap dries too rapidly to permitsatisfactory adhesion to the steel wool ribbon. At extremely hightemperatures, the moisture in the soap flashes off instantaneouslythereby partially drying the soap and reducing its adhesive properties.Typically, soap compositions at temperatures in the order of -210 F.will provide satisfactory results. Preferably, soap compositions havingtemperatures in the order of 150-190 F. are employed. The soapcomposition is sprayed onto the steel wool ribbon in an amount of 3-7grams of soap solids per 6 gram of steel wool ribbon. While the soap maybe sprayed onto either or both sides of the flattened steel wool ribbon,it is preferred in carrying out the present invention that the soap besprayed onto one side of the steel wool ribbon.

The detergent employed in the core of the present invention may be anydetergent composition which is compatible with the sprayed detergentcomposition employed and which can be extruded as a semi-solid, plastic,pastelike mass capable of substantially maintaining its position andshape as a discrete body after extrusion. It is preferred when soap isemployed that 0-3 grams of soap solids are employed per 6 grams of steelwool ribbon.

The steel wool pads are formed from steel wool ribbons having a lengthof approximately 18 inches and weighing 6 grams. The ribbons may be cutor torn before or after the soap core is applied by use of conventionalsteel wool tearing or cutting equipment. The soap core is placed uponthe steel wool and preferably located so that after formation of the padthe core is in the proximate center of the finished pad. The cut or tornsteel wool ribbon, preferably with the soap core on the soap free sideof the ribbon, is then rolled in the cylindrical form by conventionalsteel wool pad rolling equipment and then pressed in conventional steelwool pad presses to form the finished pad.

While the method of the present invention has been described withreference to the placing of a core portion on the ribbon, it has beenfound that it is possible with some scouring pad products to omit thecore and yet obtain desirable results.

The soap composition may be prepared by the following examples:

EXAMPLE I A solution is prepared by dissolving 5 pounds of potassiumcarbonate and 2 /2 pounds of sodium nitrite in 26.8 pounds of water andthe solution is heated to F. in a crutcher. 65.3 pounds of molten kettlesoap (30% H O) containing 36.6 pounds of sodium tallow soap and 9.1pounds of sodium coconut soap is added to the solution with agitation.Three pounds of dodecanol is added to the mixture. The resultant isagitated for 90 minutes while the temperature is maintained at F. Theresultant soap mixture is then ready for application to scouring pads.In carrying out the present example, steel wool strips are dipped in thefluid soap mixture at F.il0 F. and fed through the nip between two rollsto express the excess soap solution. The soap impregnated steel wool isthen cut and rolled to desired size and compressed. The finishedscouring pads are dry and provide a creamy, long lasting lather whenused.

EXAMPLE II The soap composition is prepared as in connection withExample I. To this composition a quantity of perfume and color are addedand the mixture is agitated until uniformly distributed. 1

Steel wool is then sprayed with the thereby produced resulting soapcomposition at l60il0 F. The soap is sprayed on at a rate of grams ofanhydrous soap per 18 inches of ribbon weighing 6 grams. One gram ofanhydrous soap in a semi-solid, plastic, paste-like form is thenextruded onto a ribbon being conveyed past an extrusion nozzle at18-inch intervals. The ribbon is then cut at 18 inch intervals so as toprovide each 18 inch length of ribbon with semi-solid, plastic,paste-like soap core on one end. The soap impregnated steel wool is thencut and rolled to desired size and compressed to form pads.

The soap composition is sprayed by means of a single fluid airless spraynozzle having an orifice of 0.02 inch in diameter. While a single fluidnozzle is employed in Example II, it is to be understood that anyconventional spray equipment can be employed.

EXAMPLE III A solution is prepared by dissolving 8 pounds of potassiumcarbonate and 1.5 pounds of sodium nitrite in 26.9 pounds of Water andthe solution is heated to 140 F. in a crutcher. 35.7 pounds of molten,kettle soap (70% soap-30% H O) containing 20 pounds sodium tallow soapand 5 pounds sodium coconut soap is added to the solution withagitation. Six pounds of dodecanol is added to the mixture and agitationcontinued for an additional 90 minutes while the temperature ismaintained at 150 F. The resultant soap mixture is then ready forapplication to scouring pads. In carrying out the present example 'steelwool strips are dipped in the fluid soap mixture at 150:10" F. and fedthrough the nip between two rolls to express the excess soap solution.The soap impregnated steel wool is then cut and rolled to desired sizeand compressed. The scouring pads provide a creamy, long lasting lather.

EXAMPLE IV A solution is prepared by dissolving 5 pounds of potassiumcarbonate, 2.4 pounds of sodium nitrite in 32.56 pounds of water and thesolution heated to 140 F. 60 pounds of molten, 70% solids kettle soapcontaining 52 pounds sodium tallow soap and 8 pounds sodium coconut soapis added to the solution with agitation. 3 pounds of dodecanol is addedto the mixture and agitation is continued. The resultant is employed asin conjunction with Example 11.

EXAMPLE V The formulation of the soap composition is like Example IVexcept that the quantities of the sodium tallow soap and sodium coconutsoap are reversed.

EXAMPLE VI A solution is prepared by dissolving 3.4 pounds of potassiumcarbonate, 2.7 pounds of sodium carbonate and 2.5 pounds sodium nitritein 22.5 pounds in water and the solution is heated to 140 F. To thissolution there is added with agitation 66.4 pounds of a molten kettlesoap (70% soap solids) containing 27.9 pounds of sodium tallow soap and18.6 pounds of sodium coconut soap. There is further added to thismixture with agitation 1.5 pounds of dodecanol. The resultantcombination is used as in Example II with excellent results.

EXAMPLE VII Example VI is repeated except that in the initial solutionpreparation there is additionally added 1.4 pounds of glycerine.

EXAMPLE VIII Example VI is repeated except that the carbonate mixturecomprises 5 pounds of the potassium salt and 1 pound of the sodium saltand the water content is 21 pounds; further there are used 69.5 poundsof a 70% solids kettle soap which contains a tallow to coconut soapratio of 4: 1.

EXAMPLE D( Example VIII is repeated except that the dodecanol isreplaced by a 1:1 mixture of dodecanol and tetradecanol.

6 EXAMPLE x Example VIII is further repeated with the provision of 3%polyethylene glycol (molecular weight equals 600) in the initial aqueoussolution of salts.

EXAMPLE XI 7.9 pounds of potassium carbonate, 1.45 pounds of sodiumcarbonate, and 2.5 pounds of sodium nitrite are dissolved in 23.5 poundsof water, the temperature thereof is raised to F. To this solution, withconstant agitation, there is added 61 pounds of a molten kettle soap(70% solids) with the ratio of coconut soap to tallow soap being 1.5:1(i.e. -17.1 pounds of sodium tallow soap and 25.6 pounds of sodiumcoconut soap). There is then further added 3 pounds of dodecanol whileagitation is continued. This composition is then employed as in ExampleII yielding an outstanding impregnated soap pad.

EXAMPLE XII Example XI is repeated with the additional adjuvant of 2.7pounds of glycerine to the initial salt solution.

This solution is heated to 140 and while vigorously stirring there isadded 61 pounds of a 70% solids kettle soap containing 17.1 pounds ofsodium tallow soap and 25.6 sodium coconut soap.

EXAMPLE XIV Example VIII is repeated using 3.4 pounds potassiumcarbonate, 2.7 pounds sodium carbonate, 22.5 pounds Water, 2.5 poundssodium nitrite and 1.42 pounds of glycerine in the initial solution.66.4 pounds of kettle soap are further added containing 27.9 pounds ofsodium tallow soap and 18.6 pounds of sodium coconut soap with thebalance water.

EXAMPLE XV An aqueous solution is prepared by dissolving 2.5 poundspotassium carbonate and 1.5 pounds sodium carbonate in 34 pounds ofwater heated to 140 F. and while agitating vigorously there are added 40pounds of sodium tallow soap, 20 pounds of sodium coconut soap followedby 2. pounds of dodecanol.

EXAMPLE XVI Example XV is repeated with the following changes: Only 1pound of sodium carbonate is used; the dodecanol is omitted; the 60pounds of mixed soap composition contains a tallow to coconut soap ratioof 7:5; and the water content is increased to 36.5 pounds.

EXAMPLE XVII 10 pounds of potassium carbonate and 2.5 pounds of sodiumcarbonate are dissolved in 25 pounds of water at 140 F. and whilestirring vigorously, there are added 19 pounds of sodium tallow soap and39 pounds of sodium coconut soap.

EXAMPLE XVIII Example XVII is repeated with the following changes:

The sodium carbonate level is raised to 3 pounds. The

mixed soap composition comprises 36 pounds of the tallow soap and 24 ofthe coconut soap and additionally there are added 2 pounds of dodecanol.

7 EXAMPLE XIX Each of the Examples I to IV is repeated except that thesolution of carbonate and nitrite is added to the molten soap.Comparable results are obtained.

While the present invention has been described by means of specificexamples, it is to be understood that the invention is not limitedthereto, and not only may the compositions be varied in accordance withthe general teachings herein but it is, of course, contemplated thatmany auxiliary materials, organic and inorganic be employed in thecomposition of this invention without affecting the nature thereof.These include whiteners, preservatives, perfumes, bacteriostatic agents,dyes, pigments, fillers, builders and the like.

What is claimed is:

1. A soap impregnating agent for scouring pads and the like consistingessentially of by weight the admixture of (a) 25-50 parts water (b)2.510 parts potassium carbonate 0-10 parts sodium carbonate (d) -55parts sodium high lauric acid soap (e) 5-55 parts sodium tallow soap (f)0-6 parts of a C to C saturated fatty alcohol foam builder, and

(g) 0-6 parts of a dust-reducing polyglycol, there being present atleast 25 parts of (d) and (e).

2. A composition as defined in claim 1 wherein there are present (a)30-45 parts Water (b) 5-8 parts potassium carbonate (c) 5-30 partssodium high lauric acid soap, and

(d) 1540 parts sodium tallow soap.

3. A composition as defined in claim 1 wherein there are present (a)46.4 parts water (b) 5 parts potassium carbonate (d) 9.1 parts sodiumcoconut soap (e) 36.6 parts sodium tallow soap, and

(h) 2.5 parts sodium nitrite.

4. A composition as defined in claim 3 including (f) 3 parts dodecanol.

5. A composition as defined in claim 1 wherein there are present (a)42.4 parts water (b) 3.4 parts potassium carbonate (c) 2.7 parts sodiumcarbonate (d) 18.6 parts sodium coconut soap (e) 27.9 parts sodiumtallow soap, and

(f) 1.5 parts dodecanol.

6. A composition as defined in claim 1 containing (a) 41.8 parts water(b) 7.9 parts potassium carbonate (c) 1.45 parts sodium carbonate (d)25.6 parts sodium coconut soap (e) 17.1 parts sodium tallow soap (f) 3parts dodecanol, and

(h) 2.5 parts sodium nitrite.

7. In the preparation of a scouring pad impregnated with a soapcomposition, the improvement which comprises forming an admixture of theingredients defined in claim 1 and thereafter impregnating said padtherewith.

8. The method as defined in claim 7 wherein the impregnation is effectedby means of spraying the pad with the said admixture.

9. The method as defined in claim 8 wherein the said admixture issprayed at a temperature of to 210 F.

10. The method as defined in claim 9 wherein the temperature of sprayingis 15 0" to F.

References Cited UNITED STATES PATENTS 3,337,465 8/4967 'Lancz et al.25291 3,293,684 12/1966 Tundermann 252-91 2,344,671 3/1944 Bertsch252-123 LEON D. ROSDOL, Primary Examiner W. E. SCH'ULZ, AssistantExaminer U.S. Cl. X.R. 252l23

